Mechanisms For Locking And Removing Flush Mounted Inserts

ABSTRACT

A wall-mounted component can be flush-mounted into a wallboard by first installing a panel with a receiver bracket flush into a wallboard. Once the panel is installed, the component can be inserted into the receiver bracket at which point a locking mechanism automatically or manually engages to lock the component into the wall. The locking mechanism is concealed from view so that a casual observer does not see how the component is affixed to the wall, yet is accessible from the waifs exterior for routine service and maintenance, as well as reinstallation of updated components.

This application is a divisional of U.S. patent application Ser. No.12/251,951 filed Oct. 15, 2008 which is a continuation-in-part of U.S.patent application Ser. No. 12/202,870 filed Sep. 2, 2008 and issued asU.S. Pat. No. 820,921 on Jul. 3, 2012 which is a continuation-in-part ofU.S. patent application Ser. No. 11/954,667 filed Dec. 12, 2007 andissued as U.S. Pat. No. 7,461,483 on Dec. 9, 2008 which claims priorityto provisional application 60/950,237 filed Jul. 17, 2007 and is acontinuation-in-part of U.S. patent application Ser. No. 11/566,365filed Dec. 4, 2006 and issued as U.S. Pat. No. 7,699,138 on Apr. 20,2010 which is a continuation of U.S. patent application Ser. No.11/548,381 filed Oct. 11, 2006 and issued as U.S. Pat. No. 7,963,076 onJun. 21, 2011 which claims priority to provisional application Ser. No.60/825,162 filed Sep. 11, 2006. All prior applications are incorporatedby reference in their entirety.

FIELD OF THE INVENTION

The field of the invention is locking mechanisms for wall and ceilingreceptacles.

BACKGROUND

Plasma screens, speakers, light switches, electrical outlets, recessedlighting, junction boxes and other components are conventionally mountedto walls or ceilings. Components are generally held in place on abracket using some sort of attachment mechanism. When those componentsbreak down or need to be replaced, however, the attachment mechanismoftentimes needs to be removed in order to service the component.

U.S. Pat. No. 5,152,559 to Henrichs teaches a hook and latch mechanismfor a wall panel, where the wall panel locks into place as it isinstalled on a wall bracket, and a large button in the center of thepanel releases the latch so that the panel can be removed. Having avisible unlocking device, however, can detract from the aesthetic appealand elegance of high-end wall mounts, and advertises the mechanism bywhich the component is affixed to the wallboard. Henrichs and all otherextrinsic materials identified herein are incorporated by reference intheir entirety. Where a definition or use of a term in an incorporatedreference is inconsistent or contrary to the definition of that termprovided herein, the definition of that term provided herein applies andthe definition of that term in the reference does not apply.

US 2007/0,051,862 to Monti teaches a wall-mounted speaker withprotrusions that lock into indentations in a bracket in only onedirection. There is no visible unlocking device, as the wall-mountedspeaker unlocks by pushing the speaker through the wall to the otherside. While the protrusion/indentation mechanism in Monti effectivelylocks the speaker in place within the bracket without a visibleunlocking mechanism, the speaker can only be unlocked by pushing thespeaker through to the other side of the wall. Such a configuration isnot ideal for many installations where access to the other side of thewall is not available. Additionally, an owner of the speaker may wantonly authorized persons to detach the speaker from the wall,

Thus, there is still a need in the art for locking mechanisms for wallmounts that do not have a visible unlocking mechanism, and can be pulledout from the wallboard.

SUMMARY OF THE INVENTION

The present invention provides apparatus and methods in which acomponent is installed into a wallboard receiver by locking the wallcomponent to the receiver using a concealed locking device. Typically, awallboard is a building board made for surfacing rather than forinsulating ceilings and walls. Wallboards are often made into largerigid sheets that are fastened to the frame of a building to provide asurface finish. As used herein, the term “wallboard” should be construedbroadly to mean any sort of mechanical barrier for surfacing ceilings orwalls. Wallboards can be made of any suitable material, including forexample plywood, plaster, wood, wood pulp, or gypsum.

The component is locked to the receiver using a locking mechanism thatprevents the component from being removed from the receiver, andpreferably completely immobilizes the component with respect to thereceiver. Suitable locking mechanisms include matching magnets, magnetattractors, indents, detents, compressible material, sliding bolts,recesses, pivoting latches, latch locks, screws and threaded holes.Matching parts of a locking mechanism are two parts that mate with oneanother to prevent the component from being removed from the receiver.Preferably, the locking mechanism comprises several matching magnets andmagnet attractors on the component and the receiver. A magnet attractoris defined herein as any material that has a positive magneticsusceptibility. Contemplated magnet attractors include iron, lodestone,steel, nickel, cobalt, and magnetite. A magnet attractor is attracted toa magnet when placed in close proximity to the magnet, which means thateither the magnet is pulled towards the magnet attractor or vice versa.Preferred matching magnets and magnet attractors pull the component intothe receiver without any additional forces when the magnets are locatedwithin 1, 2, or even 5 inches away from one another. (2.54, 5.08, and12.7 cm)

Whatever the locking mechanism, a cover preferably conceals the lockingmechanism from being viewed from a typical viewing angle. This can beaccomplished by physically placing or sliding a cover over the lockingmechanism, but is typically accomplished by placing the lockingmechanism on any side but the front side of the component. A key couldbe used engage the locking mechanism, however, the locking mechanismpreferably automatically engages as the component slides into thereceiver so that a user looking at the front of the component does notsee how the component is attached to the receiver.

An electronic remote could unlock the locking mechanism, for example aradio frequency transmitter or a passive RFID tag, but the key to unlockthe component from the receiver is preferably a low tech solution. Forexample, a magnet could slide a bolt or latch to the side, or ascrewdriver could unscrew a bolt running through the component and thereceiver. A user could also simply overpower the locking mechanism bypulling the component from the receiver using a gripping surface, forexample a handle, outcropping, or a loop. Where the front surface of thecomponent is without a gripping surface, a vacuum or magnetic forcecould be used. Vacuum grippers could provide a powerful vacuum force bycombining a lever with a suction cup, and electromagnets or lodestonescould provide a powerful magnetic force.

The bracket is preferably located within a panel that is installed inthe wallboard for ease of installation. Preferred panels havecompositions and thicknesses that match the wallboard to which they arebeing finished, in terms of thickness, composition, and so forth. Wherethere are differences in composition or thickness, it is preferred thatthe moisture absorption rate and the thermal expansion rate of the paneland the wallboard differ by no more than 30%, 20%, 10% or 5% from oneanother to prevent cracking and fraying. Contemplated panel materialsinclude polymers, plasters, woods, fiberboards, and gypsum. Since thepanel will likely be anchored to a support structure using a screw,nail, or similar attachment mechanism, preferred panels have a pluralityof screw hole positions, for example depressions, markings, or screwholes, that indicate potential screw or nail positions. Panels can havefactory cut openings that receive the multiple receivers, and in suchcases the receivers would likely be glued to the panel material toeliminate any gaps. More advantageously, the panel material can bemolded around the receivers so that there is essentially no gap betweenpanel material and receivers.

A receiver can be affixed to an opening in the panel, which typicallyextends from a front side of the panel to the back side of the panel.Receivers can range from a simple rim disposed on the inside of theopening to an extensive bracket and housing extending out the back ofthe panel. In any event, completed assemblies preferably have little orno discernable gap between the panel and the receiver. This can beaccomplished in any suitable manner, including for example, accuratelycutting the opening into which the receiver is installed and then gluingthe receiver to the panel. Where the panel comprises a formed substancesuch as drywall, another option is to form the panel around thereceiver.

In preferred embodiments, a receiver has a spackle shield that coversthe opening, which can include useful installation tools, for example alevel, installation screws, or installation instructions. In thefigures, each receiver also has an optional spackle rim that extendsoutwardly from the front surface of the panel by a small distance.Preferred distances are less than ½ inch (1.27 cm), more preferably byonly ⅛ inch (3.175 mm), and even more preferably 1/16 inch (1.5875 mm).Spackling compounds can then be smoothed over the surface of thewallboard and panel up to the spackle rims to achieve a contiguousvisual appearance. While the surface of the wallboard is typically flat,the junction between the wallboard and the panel does not necessarilyhave to be flat.

Panels are typically installed into the wallboard by first approximatingthe edges of the panel with the edges of the wallboard. “Approximating”is defined herein to mean bringing the edges near or towards one anotherso that the junction or gap between the edges is less than 10 mm (0.394in), 5 mm (0.197 in), or even 2 mm (0.079 in). If the junction or gapbetween the edges is larger, a buffer can be attached to the edge of thepanel before installation, or one or more shims can be installed intothe junction. The junction can then be concealed using a suitableconstruction method, for example taping or plastering over the junction.Providing a pre-fabricated panel designed to accept specific componentsgreatly facilitates installation by eliminating the need for on-siteprecision measurements.

All types of components are contemplated for installation, butespecially including components having electrical parts. For example,speakers, lights, switches, wall plugs, in-wall controls (audio, video,fan), thermostats (HVAC controllers), fire sprinklers, fire alarms andsmoke alarms, minors, video screens, kitchen appliances, picture frames,signage, intercoms, air vents, vacuum outlets, security panels, and iPoddocks and ports are all contemplated components.

The contemplated locking mechanisms allow a user to easily service acomponent in a wallboard while concealing the locking mechanism fromview, facilitating the elegant flush-mounted appearance. As definedherein, “servicing” means installing, uninstalling, or otherwisemaintaining the component and/or receiver,

Various objects, features, aspects and advantages of the presentinvention will become more apparent from the following detaileddescription of preferred embodiments of the invention, along with theaccompanying drawings in which like numerals represent like components,

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a front perspective view of a component and a matchingreceiver in a wallboard.

FIG. 2 is a front perspective view of the component mounted in thematching receiver of FIG. 1.

FIGS. 3A-3B are simplified horizontal cross-sections of the componentand receiver of FIG. 2, taken along line 3-3.

FIGS. 4A-4B are horizontal cross sections of a component that is pulledout of a receiver by applying a magnetic gripper to the front of thecomponent.

FIGS. 5A-5B are horizontal cross sections of a component that is pulledout of a receiver by applying a vacuum gripper to the front of thecomponent.

FIG. 6 is a horizontal cross section of a component and receiver thatlock using matching indents and detents.

FIG. 7 is a horizontal cross section of a component and receiver thatlock using compressible material lining the receiver

FIGS. 8A-8B is a horizontal cross section of a component and receiverthat lock using matching sliding bolts and recesses.

FIGS. 9A-9D is a horizontal cross section of a component and receiverthat lock using matching pivoting latches and protrusions.

FIG. 10A is a horizontal cross section of a component and receiver thatlock using matching threaded bolts and threaded holes.

FIGS. 10B-10C are front plan views of the component of FIG. 10A.

FIGS. 10D-10F are horizontal cross section views of a shortenedcomponent and receiver of FIG. 10A, with a magnetic faceplate attached.

FIG. 11 is a plan view of a panel having an opening, and a receiverdisposed in the opening.

FIG. 12 is a front perspective view of the receiver in FIG. 11.

FIG. 13A is a simplified vertical cross-section of the panel of FIG. 11,taken along line 13-13, installed in a wallboard with an attachedcomponent.

FIG. 13B is a blown up view of the circled portion of FIG. 13, takenalong line 14-14.

FIG. 14 is a front perspective view of the receiver of FIG. 12positioned to couple with a bracket backing.

FIG. 15 is a blown up view of the circled portion of FIG. 13, takenalong 14-14, with the bracket and bracket backing of FIG. 15.

FIG. 16A is a front perspective view of a panel being affixed to twostuds in a wall, the panel having a spackle shield covering theopenings.

FIG. 16B is a front perspective view of the panel of FIG. 17A, aroundwhich drywall has been installed.

FIG. 16C is a front perspective view of the panel and drywall of FIG.17B, showing mesh tape.

FIG. 16D is a front perspective view of the panel and drywall of FIG.17C, where the mesh tape has been covered by spackle.

FIG. 16E is a front perspective view of the panel and drywall of FIG.17C, where the spackle shields have been removed to show the openings.

FIG. 17A is a perspective view of two structures in a building (e.g.walls or wall and ceiling), in which an opening has been cut to receivea panel assembly.

FIG. 17B is a perspective view of the two structures of FIG. 18A, inwhich the panel assembly has been placed within the opening.

FIG. 17C is a perspective view of the two structures of FIG. 18B, inwhich the approximated edges of the panel assembly and the wall havebeen finished to provide a superficially continuous junction.

FIG. 18 is a perspective view of a panel assembly being formed bypouring a panel material into a mold.

DETAILED DESCRIPTION

In FIG. 1, a component mounting system 100 generally includes awallboard 110, a receiver 120, and a component 130. It should beappreciated that while component 130 is a speaker, any suitablecomponent mounted to a wall could be used, for example plasma screens,in wall art panels, in wall cabinets, windows, wall outlets, securitysystems, fuse boxes, light switches, lighting, sprinkler systems, smokedetectors, and so forth. While the receiver is generally shaped andsized to fit particular electronic devices, for example a rectangle fora light switch or a circle for a ceiling light, the universal receivermay be used that can accommodate a variety of electronic devices. To fitthe component to a universal receiver, the component could consist of anouter casing that fits around the electronic device and couples to theuniversal receiver.

As shown in FIG. 2, component 130 can be inserted into receiver 120 tocreate a flush-mounted appearance within wallboard 110. Flush-mountingmeans to make a surface of the component substantially flush with thesurface of the wallboard. Although the portions of the wallboard 110depicted in the FIG. 2 is substantially flat, those skilled in the artwill appreciate that the structure could be curved, slanted, or havecurved/slanted portions in any direction. Preferably, a lockingmechanism (not shown) locks component 130 to receiver 120 to prevent thecomponent from being removed from the receiver. In an exemplaryembodiment, the locking mechanism completely immobilizes component 130within receiver 120 until the locking mechanism is disengaged. Thelocking mechanism is hidden from view once the component is installed inthe receiver so as not to disturb the elegant flush-mounted Contemplatedlocking mechanisms are disclosed in FIGS. 3-10, and are discussed indetail below.

In FIGS. 3A and 3B, a magnet locking mechanism 300 generally comprisesmagnet attractors 310 and magnets 320. Magnets 320 pull component 130into receiver 120 so that the front portion of component 130 is flushwith the front of wallboard 110. White magnets 320 do not have to beparticularly strong, magnets 320 are preferably strong enough to pullcomponent 130 into the locked position when magnets 320 are less than 5inches (12.7 cm), 2 inches (5.08 cm), or 1 inch (2.54 cm) from magnetattractors 310. It should be appreciated that magnet attractors 310could be switched with magnets 320, or could be magnets themselves. In apreferred embodiment, magnet attractors 310 are magnets, and magnets 320are electromagnets. A remote control (not shown) could then reverse thepolarity of magnets 320 to “eject” the component from the receiver whenmaintenance needs to be performed. Alternatively, a wire (not shown)could run to the front of component 130 and surround magnet attractors310 so that when a current is applied to the wire, the magnet attractors310 reverse polarity to “eject” the component from the receiver.

Component 130 has electrical male connectors 330 are banana jacks thatare sized, spaced, and oriented to mate with electrical femaleconnectors 340 as component 130 is being mounted in receiver 120. Bananacouplings are preferred because they provide a particularly robustconnection, and it is relatively easy to orient the plug to the jack. Ofcourse, one could use a single plug and jack provided that a properelectrical pathway is established, for example, an RF connector. Allother suitable types of connectors are also contemplated, including forexample inductive connections (not shown), simple bent wire or otherbump connectors (not shown), loudspeaker connectors (not shown), D-subconnectors (not shown), and combinations thereof. It should beappreciated that male connectors 330 and female connectors 340 could beswitched with one another without departing from the scope of theinvention.

Regardless of the type of connectors and manner of providing theelectrical connections, it is preferred that the electrical connectionis a substantially automatic. As the component is mounted in thereceiver, the female electrical connectors 340 should mate with the maleelectrical connectors 330 without a separate act. In FIG. 3A and 3B, ascomponent 130 is placed within receiver 120, the magnetic force ofmagnets 320 upon magnet attractors 310 pulls male electrical connectors330 into female electrical connectors 340. Forcing the user to manuallymate the connectors in a separate act, whether with a wire nut orotherwise, is thought to be much less preferable.

It should be appreciated that electrical connectors may not need to beinstalled at all, particularly where the component does not require anelectrical connection, for example in the case of a picture frame or awireless doorbell.

In FIGS. 4A and 4B, instead of using an electromagnet of reversedpolarities to eject the component from the receiver, a magnet gripper410 could be used with a magnet attractor 420 to overpower the magneticforce between magnet attractor 310 and magnet 320. It should beappreciated that the magnetic force between magnet gripper 410 andmagnet attractor 420 should be much stronger than the magnetic forcebetween magnet attractor 310 and magnet 320. It should also beappreciated that if component 130 is an electronic device, that magnetattractors 310 and 420 should be located well aware of any electricalmachinery that would be negatively affected by a strong magnetic force.An additional magnet gripper (not shown), or a single magnet gripperwith an additional handle, could be used for a user to pull thecomponent out of the receiver with two hands instead of one.

In FIGS. 5A and 5B, a vacuum gripper 510 is used instead of a magnetgripper to overpower the magnetic force between magnet attractor 310 andmagnet 320. Vacuum gripper has a lever 512 that is attached to suctioncup 514 such that when lever 512 is activated, air is removed fromsuction cup 514. When lever 512 is pulled while suction cup 514 abutsthe fiat surface of component 130, the absence of air in suction cup 514provides a vacuum force that locks vacuum gripper 510 to the front ofcomponent 130. From that point, a user can simply pull on vacuum gripper510 to remove component 130 from receiver 120.

In FIG. 6, an indent/detent locking mechanism 600 generally comprisesindents 610 and detents 620. Indents 610 are sized, spaced, and orientedto mate with detents 620 as component 130 is being inserted intoreceiver 120. Preferably, detents snap into place around indents 610without locking into place, so that component 130 can be pulled out ofreceiver 120 without damaging the indent/detent mating. Detent 620 couldalso be a push-push latch, so that component 130 could be disengagedmerely by pressing on the front of component 130. In a preferredembodiment, indents 610 are male banana jacks and detents 620 are femalebanana jacks that provide an electrical communication between component130 and receiver 120 and a locking mechanism between component 130 andreceiver 120.

In FIG. 7, a compressible locking mechanism 700 generally comprises acompressible material 710 that fits in the gap between the rear portionof component 130 and the receiver 120. Compressible material 710 ispreferably an elastic polymer or fabric that has a tendency to return toits own shape. The combined elastic forces of compressible material 710and the vacuum force of pushing air out of receiver 120 holds component720 in place within receiver 120. In this particular example, theoutside thee plate 720 is larger than the rear portion of component 130.

In FIG. 8, a sliding bolt locking mechanism 800 generally comprisessliding bolts 810 in component 130 and recesses 820 in receiver 120.Sliding bolt 810 is a magnet attractor that is pulled into place bydrawing magnet 830 across the surface of component 130. In thisparticular example, component 130 has a handle 840 that extends from afront surface of component 130 to allow a user to pull component 130away from receiver 120 once the sliding bolt mechanism is unlocked.

In FIGS. 9A-9D, a pivoting latch locking mechanism 900 generallycomprises pivoting latches 910 in component 130, latch lock 920 inreceiver 120, and magnet attractor 930 in component 130. As component130 is inserted into receiver 120, pivoting latches 910 pivot into arecess (not shown) in component 130 and then snap into latch locks 920,preventing component 130 from being pulled out of receiver 120. Latchlock 920 is shown as a beveled recess, but could be a protrusion or anyother suitable latch lock that prevents component 130 from being pulledout of receiver 120. Here, pivoting latches 910 are also made of amagnet attracting material. When magnet gripper 410 is applied to magnetattractor 930, magnet attractor 930 acts as a magnet, pulling latches910 out of latch locks 920, so that component 130 can then be pulled outof receiver 120.

In FIGS. 10A-10C, a screw locking mechanism 1000 generally comprisesscrews 1010, screw holes 1020 in receiver 120, and a cover 1030. Screws1010 are threaded and run through the entirety of component 130 and intoscrew holes 1020 to hold component 130 against receiver 120. It shouldbe appreciated that screws 1010 could also be angled towards a closerwall of receiver 120, or could be fully threaded along the entire lengthof the screw. As seen in FIG. 10B, the heads of screws 1010 are visiblefrom the front of component 130. Thus, after installation, cover 1030 ispositioned in the recess, and magnetically, mechanically or otherwiseheld in place to provide an even front surface to component 130.

In FIGS. 10D-10E, the screw locking mechanism 1000 also has a magneticfaceplate 1030 with magnet attractor 1040 and magnets 1050. Magnets 1050hold the faceplate against component 130 by coupling to the heads ofscrews 1010. It should be appreciated that component 130 could compriseother magnet attractors that help couple the magnetic faceplate to thecomponent. Faceplate 1030 could be removed with either a magnet gripper410 or another suitable gripping device, for example a vacuum gripper.

As shown in FIG. 10F, faceplate 1030 could also be held in place andremoved using matching indents 1060 and spring detents 1070 to form apush-push mechanical coupling. While the faceplate coupling alsopreferably conceals the locking mechanism, all other suitable couplingsare contemplated.

In all of the embodiments, the receiver is preferably preinstalled in apanel that is then installed in a wallboard to provide better supportfor the component. In FIG. 11, a component mounting apparatus 1100generally includes a panel 1110 with an opening 1120, and a receiver1140 disposed in the opening 1120, and attachment wings 1170A-1170D. Itshould be appreciated that while each receiver is sized and dimensionedto hold a specific component, the receivers could be identical to oneanother to create a “universal bracketing system” that can holdcomponents of various sizes.

Panel 1110 is a piece of gypsum board, woof:, plastic, or other material(or combination of materials) sufficiently strong to support a speakeror other desired component between two studs of a wall, or joists orother supports in a ceiling. Where plywood is used as the panelmaterial, for example, the panel might be as thin as ¼″ (6.35 mm), butwould more preferably measure at least ½″ (12.7 mm) or ⅜″ (19.05 mm).Preferred materials include wallboard, Medium Density Fiberboard (MDF),High Density Fiberboard (MDF), Acrylonitrile Butadiene Styrene (ABS),and other materials that closely match various characteristics ofdrywall, Multiple materials could be used, for example mixed in with oneanother, alternating, layered on top of one another, or a combination.Preferably, the material has equal moisture absorption and coefficientof thermal expansion as the surrounding wallboard, while having greaterdurability and strength for attaching heavy components directly to thepanel. For example QuietRock® 525 could be a paneling material usedwhere the wallboard comprises drywall.

Panel 1110 is generally about twenty inches (about 50 cm) to twenty-fourinches (about 60 cm) wide, but panel 1110 can have any other suitabledimensions, even for example, up to the size to replace an entire sheetof wallboard. Narrower panels are also contemplated, although they wouldlikely not have a sufficient width to extend between wall studs orceiling joists. It is preferable for the panel 1110 to have a width ofat least six inches (15.24 cm) or twelve inches (30.48 cm) greater thanthe spacing between studs, which allows the installer considerablygreater flexibility in positioning the panel on the wall. Lateral wings(not shown) could be attached to the perimeter of panel 1110 to extendthe width for installations where the studs are spread apart at agreater distance from each other than normal. While panel 1110 is shownas a substantially planar apparatus, panel 1110 can be concave, convex,or any other shape to either match the shape of the wallboard, or tointroduce a non-planar surface to the wallboard.

Hole primers 1112 are spaced approximately 1 inch (2.5 cm) from center,a diameter of 0.375 in (9.525 mm), and are approximately ¼ in (6.35 mm)deep, but can be shaped and configured in other suitable ways. A “holeprimer” is a concave hole deepest in the center that helps an installerdrill a screw or hammer a nail in a designated place without slipping.The diameter of the hole primer is preferably larger than the diameterof the screw head or nail head used so as to prevent the head of thescrew or nail from leaving an unsightly bump on the surface of thewallboard after spackling. Other suitable receivers are contemplated,for example visual marks or pre-drilled and threaded screw holes.

Opening 1120 can also be of any suitable shape and size. Preferredopenings are rectangular to accommodate common rectangular components,for example light switches, wall outlets, speaker volume controls, andhome security systems. However, the openings could also be oval orcircular or any other desired shape. The area of the opening isgenerally dependent on the size of the component, and can range up to 80in² or larger. Especially preferred openings have an area of at least 20in², 40 in²; 60 in², and even 80 in². Nevertheless, for stability, it iscontemplated that the panel have openings with a length that is no morethan half or one third the length of the panel.

In some cases it may be desirable to include multiple openings formultiple components. Openings with varying height could be aligned alongtheir top or bottom edges, aligned along a centerline, or could bearranged in a staircase fashion with a top edge aligned to a bottomedge. Openings could be cut at a job site or elsewhere by an installer,but are more conveniently precut (or molded to include the opening) atthe manufacturer. It is possible for a panel to have punch out openingsor perhaps cutout lines to facilitate selection of the position of theopening at the job site, but those options are currently disfavoredrelative to a manufactured pre-cut or molded opening and a relativelylarge panel.

The top, bottom, and side wings 1170A-1170D, respectively, preferablyextend from the corresponding edges of the panel 1110 by at least aboutone inch (2.54 cm), which is deemed to be sufficient space toconveniently drive a nail or screw into a stud. It is also contemplated,however, that at least one of the wings 1170A-1170D can extend muchlonger, perhaps 24 to 30 inches (about 60-75 cm) or more. Such longwings can accommodate odd installations where the studs are spread apartat a greater distance from each other than normal. Wings 1170A-1170D arepreferably made of a metal mesh, but can include of any suitablematerial or materials so long as the material(s) provide(s) sufficientshear strength to support the panel 1110 and the component (not shown).Metal mesh is also desirable because the wings are advantageouslyrelatively thin, so as not to push out the overlying wallboard, andmetals can provide considerable strength with thickness of less than 100mils. It should also be appreciated that although wings 1170A-1170D aredescribed herein by separate numerals, they may well be one continuouspiece of material.

Receiver 1140 is preferably sized and dimensioned to fit snugly intoopening 1120, but in any event is screwed, glued, clamped, or areotherwise securely attached to the panel 1110. The secure attachment isimportant since in at least some embodiments, the component housing willbe attached to the receiver rather than being directly attached to thepanel 1110. The receiver is preferably molded from polyethylene or othersufficiently strong and durable thermoset plastic. A front of receiver1140 is shown in greater detail in FIG. 12, and includes holes 1142 forscrews (not shown), a recess 1144 into which a component cover (notshown) can be removably secured via a holding mechanism, and a rim1140A, and optional magnets 1146 or an optional press fit (not shown).

A spackle shield (not shown) preferably covers the opening of thereceiver to prevent mud or drywall from splashing to the other side ofthe panel, and can be removed after spackling. This is particularlyhelpful for when an electronic component is pre-installed behind thepanel before spackling. The spackle shield (not shown) can have optionallevel (not shown) to help ensure that the panel is being installedhorizontally. Other devices that assist in installation can be providedin the spackle shield, for example a laser leveler to help align severalpanels with one another or a compartment that stores extra screws andmagnets.

FIGS. 13A-B shows a side view of panel 1110 and receiver 1140. The rim1140A is sized and dimensioned to extend outwardly beyond a front of thepanel 1110 by a very small distance 1141, which provides a lip that canreadily be used as a stop against which to spread a spackling compound,for example plaster or drywall. Preferred such distances 1141 are lessthan ⅛ inch, and preferably about 1/16 inch, or in metric terms about1-3 mm. Preferably, the panel has a thickness of at least ¼ inch (6.35mm). Also shown in FIG. 13B is an attachment member 1148 that helpssecure receiver 1140 to panel 1110. A screw hole (not shown) can beprovided in attachment member 1148 to help affix receiver 1140 to panel1110.

It should be appreciated that the rim could be separable from the panel.Thus, for example, the rim could be a separately molded piece ofplastic, metal or composite that is installed into the opening by theinstaller, or at a factory.

As seen in FIGS. 14 and 15, a receiver backing 1180 with screw holes1182 could be used to clamp receiver 1140 to panel 1110. In thisembodiment, attachment member 1148 fits within recess 1114 on the frontof panel 1110 and receiver backing 1180 fits within recess 1116 on theback of panel 1110. Screw 1184 threads through screw holes 1142 and1182, and finally through nut 1186 to provide a clamping force aroundpanel 1110. Clamping receiver 1140 to panel 1110 provides a secureconnection without the need for expensive glues or adhesives.

In FIG. 16A, the panel 1110 is affixed to two studs 1210A, 1210B in awall, and screws 1215 are inserted through hole primers 1112 and thepanel 1110 on the right side, and through attached flange 1170. Panel1110 shows opening 1120 with a spackle shield covering the receiver. Ofcourse, the positioning and orientation of the panel could be varied inany suitable manner with respect to the studs, 1210A, 1210B, includingmoving the panel 1110 higher or lower, left or right, or even tiltingthe panel clockwise or counterclockwise. Similarly, the studs shouldalso be interpreted herein as emblematic of any support structures of awall, whether or not such structures are technically considered to bestuds. In addition, a greater or lesser number of screws could be used,or inserted in some other arrangement than that shown to provide greateror lesser support. The screws could also be replaced or supplemented bysome other attachment means such as an adhesive.

Those skilled in the art will appreciate that the combination of paneland receiver could be provided in several different ways. The panel andreceiver could, for example, be joined together at a job site, andindeed the panel could even be “manufactured” at the job site by cuttingor punching out the opening. More preferably, however, the panel andreceiver are provided as an item of manufacture to the installer by asupplier or manufacturer. The rim of the panel can be pre-installed tothe panel. Thus, in various embodiments a kit could contain one or moreof a panel, a receiver (or at least a rim around the edges of an openingin the panel), a speaker housing, a spackle shield, and installationscrews. The installer would then provide whatever labor is appropriatefor the installation, including optionally installing the receiverand/or rim, optionally installing the spackle shield, and optionallymounting the speaker into the speaker housing to the back side of thepanel. It is also contemplated that the speaker can be pre-installedinto the panel before installation. Alternatively the combination of thepanel and receiver can be mounted before installing a rim on the opening

In FIG. 16B drywall 1220 or other wallboard has been installed on allfour sides around the panel 1110, and coupled to the wings using screws1215. Where wings are present, as in the embodiment depicted, thedrywall 1220 overlays the wings, but the wings are sufficiently thin sothat the drywall is not noticeable raised. Those skilled in the art willappreciate that although FIG. 16B shows drywall 1220 surrounding thepanel 1110 as a single piece; it is entirely possible that the drywallcould comprise multiple pieces (not shown). It is also contemplated thatinstallation of the drywall 1220 might be delegated to drywaller orother tradesman distinct from the panel installer. Nevertheless, theprocess of installing the panel on one or more wall supports is deemedto include the step of positioning the panel so that it can beapproximated in an end-to-end fashion by a piece of wallboard or otherwall section.

In FIG. 16C mesh tape 1230 is applied along the juxtapositions or otherapproximations between edges of the panel 1110 and edges of the drywall1220. Here again, this step is usually delegated to a professionaldrywaller, but could be accomplished by the installer of the panel,regardless of which person actually does the work,

In FIG. 16D the mesh tape is covered by a spackling compound, and isready for painting, wallpapering, or other surface coating. Preferably,the spackling compound is smoothed over the entire front surface of thepanel to the lips of opening 1120. As used herein, the terms “spackle”and “spackling” should be interpreted as broadly as possible, to includefor example plaster and plastering of any type. One objective is toprovide a smoothed out surface that completely or substantially hidesthe joints between edges of the panel and edges of the drywall

In FIG. 16E, the spackle shield is removed from opening 1120 and acomponent can be installed in the new uniform wallboard 1220.

In FIG. 17A an installation 1700 generally includes wallboards 1710,1720, an opening 1714 on structure 1710, and a panel assembly 1730 thatwill installed into the space 1714, as shown by arrow 1740.

As used herein, the term “assembly” means an object that has multiplecomponents or functional portions. Thus, the term comprises: (a)multiple pieces that are coupled together in some manner, eithertemporarily or permanently; and also (b) a single molded object withmultiple functional components. By way of example, panel assembly 1810in FIG. 18 is a panel assembly molded as a single piece.

In typical installations, the wallboards 1710, 1720 would be adjacentvertical walls, or a vertical wall and a ceiling, and FIG. 17A should beinterpreted to include all such embodiments. Thus, for example, wherewallboards 1710, 1720 are interpreted to be vertical walls, members1712, 1722 could be studs. Where wallboard 1710 is interpreted as aceiling, members 1712 could be joists, and members 1722 could behorizontal struts. Although the portions of the wallboards 1710 and 1720are depicted in the figure as substantially flat, those skilled in theart will appreciate that the structures could be curved, or have curvedportions. In addition, those skilled in the art will appreciate thatwallboard 1710 could exist independently of wallboard 1720.

Wallboards 1710, 1720 would typically comprise drywall, which term isused herein generically to include all manner of wallboard, fiberboard,gypsum board, GWB, plasterboard, Sheetrock® and Gyproc®, and so forth.Additionally or alternatively, wallboards 1710, 1720 could compriseother materials, including for example polymers, masonry, ceramics, andacoustic ceiling tile materials or other composites.

Wallboards 1710, 1720 can have any suitable dimensions, from only a fewsquare feet or less, to hundreds of square feet or more. Wallboards1710, 1720 will usually, however, have relatively small thicknesses ofbetween ¼ and 1″ in thickness.

Panel assembly 1730 can be produced at a job site, for example, bycutting a hole out of a piece of drywall. The piece being used in suchinstances can be cut out from an existing vertical wall or ceiling, andor can be completely new to the job site. Either of those methods couldwork adequately for drywall, acoustic ceiling tile and other materialsthat are fairly easy to cut, but for difficult to cut materials,including for example polymers, masonry, and ceramics, the panelassembly can be most conveniently produced in a factory where the panelis dried or cured around a form (see FIG. 8) to define the opening.

As discussed above with respect to FIGS. 11-16, the opening 1734 of FIG.17A can be any suitable size, shape, or number. As currentlycontemplated, it is desirable that the total front facing area consumedby the opening be relatively small with respect to that of the panel1732. That ratio is preferably at least 3, more preferably at leastfive. Viewed from another perspective, it is preferred that the panel1732 extend in at least one direction at least 3 inches (7.62 cm) fromthe closest edge of the opening 1734 for light or other simple switches,electrical outlets and so forth, and at least 5 inches (12.7 cm) forlights, more complicated switches and other controllers, speakers and soforth. Where the component has a front-facing surface area of at least25 in² (about 160 cm²), the panel 1732 extends in at least one directionat least 12, 117, or even 24 inches (about 30, 45, or 60 cm) from theclosest edge of the opening 1734.

In FIG. 17B the panel assembly 1730 has been placed within the space1714. There will almost always be some gap between the edges of thepanel assembly 1730 and those of the surrounding structural component1710, ranging in typical installations from zero (where the panelassembly 1730 is abutted against the structural component 1710), andperhaps 1/17″ (3.175 mm) to ¼″ (6.35 mm). Indeed, there will almostalways be multiple different gaps around the edge of the panel assembly.Where the workmanship is sloppy, or the project is especially difficult,the gap in some sections can be larger. In addition, it is contemplatedthat an intermediate member (not shown), as for example a paper, shim,or even a frame can be installed in the gap between the panel assembly1730 and the structural component 1710. As long as the edges of theassembly and the wallboard are somewhat near each other, and the gap canbe finished and concealed such that an at least superficially continuousjunction is established between them, the edges are considered to beapproximated.

In FIG. 17C the approximated edges of the panel assembly and thewallboard have been finished to provide an at least superficiallycontinuous junction. As used herein the term “at least superficiallycontinuous junction” refers to a junction that appears to casualobservation to be seamless. By way of example, a good workman-like jobin taping and plastering adjacent sections of wall board is consideredherein to produce an at least superficially continuous junction,especially where subsequent painting or wallpapering eliminates any seamapparent c casual observation.

FIG. 18 is a perspective view of a panel assembly 1810 being formed bypouring a panel material from container 1840 into a mold 1820. Thisprocess brings the poured material right up against the frame portionthat defines the opening 1830, regardless of any irregularity or otherdifficulties with the shape of the opening. All manner of panelmaterials are contemplated, including for example curable plastics, andmasonry composites.

Thus, specific embodiments and applications of concealed lockingcomponents for wallboard mounts have been disclosed. It should beapparent to those skilled in the art that many more modificationsbesides those already described are possible without departing from theinventive concepts herein. The inventive subject matter, therefore, isnot to be restricted except in the spirit of the appended claims.Moreover, in interpreting both the specification and the claims, allterms should be interpreted in the broadest possible manner consistentwith the context. In particular, the terms “comprises” and “comprising”should be interpreted as referring to elements, components, or steps ina non-exclusive manner, indicating that the referenced elements,components, or steps may be present, or utilized, or combined with otherelements, components, or steps that are not expressly referenced. Wherethe specification claims refers to at least one of something selectedfrom the group consisting of A, B, C . . . and N, the text should beinterpreted as requiring only one element from the group, not A plus N,or B plus N, etc.

1. A system for servicing a device mounted in a wallboard, comprising; amounted device having a front side and at least one non-front side; apanel having an opening; a receiver disposed in the opening and definingan at least partially enclosed space extending from the panel; a lockingmechanism that removably couples the mounted device to the receiver suchthat the front side of the mounted device is flush with the panel andthe at least one non-front side is hidden; and wherein the lockingmechanism comprises a first detent and a first indent, one of which isdisposed on the at least one non-front side of the mounted device andthe other of which is disposed on an inner surface of the enclosedspace; and wherein the first detent and first indent are positioned,sized, and dimensioned to engage one another to provide a firstengagement force.
 2. The system of claim 1, wherein the panel is moldedaround the receiver.
 3. The system of claim 1, further comprising acover.
 4. The system of claim 3, wherein the cover comprises a slidingplate that covers the locking mechanism.
 5. The system of claim 3,wherein the cover comprises the front side of the mounted device.
 6. Thesystem of claim 1, wherein the locking mechanism further comprises asecond detent and a second indent that are positioned, sized, anddimensioned to mate with one another.
 7. The system of claim 1, furthercomprising a gripper that engages the front side of the mounted deviceto provide a second engagement force.
 8. The system of claim 7, whereinthe second engagement three is larger than the first engagement force.